CLUTCH UNIT (for C59): Installation

1. Insert SST into the clutch disc assembly, then insert them both into the flywheel sub-assembly.

   SST 09301-00110 

   NOTE: Insert the clutch disc assembly in the correct direction.
   Fig 1: Installing Clutch Disc Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the matchmark on the clutch cover assembly with the one on the flywheel sub-assembly.
2. Following the procedure shown in the illustration, tighten the 6 bolts in order, starting with the bolt located near the knock pin at the top.

   Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf) 

   HINT:

   • Following the order in the illustration, tighten the bolts evenly one at a time.
   • Move SST up and down, right and left lightly after checking that the disc is in the center, and tighten the bolts.

   SST 09301-00110 

   Fig 2: Installing Clutch Cover Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment.

   Maximum non-alignment: 

   0.9 mm (0.0354 in.) 

2. If the alignment is not as specified, adjust the diaphragm spring tip alignment using SST.

   SST 09333-00013 

   Fig 3: Checking Diaphragm Spring Tip Alignment

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the release fork support onto the transaxle assembly.

   Torque: 37 N*m (375 kgf*cm, 27 ft.*lbf) 

   Fig 4: Identifying Release Fork Support

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the clutch release fork boot to the manual transaxle.
   Fig 5: Identifying Clutch Release Fork Boot

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply release hub grease to the contact surfaces between the release fork and release bearing assembly, release fork and push rod, and release fork and fork support.

   Grease: 

   Toyota Genuine Release Hub Grease or equivalent 

2. Install the release fork onto the release bearing assembly with the clip.

Fig 6: Locating Grease Applying Area On Release Fork And Release Bearing Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply clutch spline grease to the input shaft spline.

   Grease: 

   Toyota Genuine Clutch Spline Grease or equivalent 

   NOTE: Do not apply grease to portion A shown in the illustration.
2. Install the clutch release bearing with the release fork onto the transaxle assembly.
   NOTE: After installation, move the fork back and forth to check that the release bearing slides smoothly.
   Fig 7: Locating Grease Applying Area On Input Shaft Spline

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

See INSTALLATION .